Heat exchanger

ABSTRACT

A heat exchanger, for example a charge-air cooler, may include at least two bases respectively having a passage for receiving a plurality of fluid-conducting tubes on a longitudinal end side. The heat exchanger may include at least one collecting chamber arranged on at least one of the at least two bases, and at least one lateral part received via a longitudinal end area at least partially in an end-side passage of an associated base of the at least two bases. The longitudinal end area of the at least one lateral part may have a beam shape and at least one recess. The longitudinal end area of the at least one lateral part may further have a cross-sectional surface that is smaller than a cross-sectional surface of the end-side passage of the associated base.

CROSS-REFERENCE TO RELATED APPLICATION

This application claims priority to German Patent Application No. 10 2014 219 082.7 filed on Sep. 22, 2014, German Patent Application No. 10 2014 219 210.2 filed on Sep. 23, 2014, and International Patent Application No. PCT/EP2015/070602 filed on Sep. 9, 2015, the contents of which are hereby incorporated by reference in their entirely.

TECHNICAL FIELD

The present invention relates to a heat exchanger, in particular a charge air cooler.

BACKGROUND

From EP 2 498 040 A2 a heat exchanger with two bases is known, which respectively have passages for receiving, on the longitudinal end sides, fluid-conducting in particular coolant-conducting, tubes. On the two bases respectively a collecting chamber is arranged. Two lateral parts are also provided, which are received, with their respective longitudinal end areas, at least partially in respective end-side passages of the bases.

From DE 10 2007 025 878 A1 a further heat exchanger is known, consisting of a block having tubes and ribs, and at least one base having passages, wherein the tubes have tube ends which are able to be received in the passages and form tube/base connections with the base, which are at least partially reinforced by an additional sheet metal part. The sheet metal part has insertion openings for the tube ends and is arranged on the side of the base facing the block. Hereby, the base and the tube/base connections are to be relieved in a simple and favourably priced manner, in order to be able to guarantee the tightness even in the case of more intensive stresses.

Basically, there are two different embodiments for a base in heat exchangers for an application in the automotive field. In the first embodiment, the base has a circumferential channel, in which a seal lies. In this embodiment, an associated lateral part is directed through an end-side passage, which differs in its configuration or respectively its dimensions from the other passages provided for the flat tubes. As a consequence of this, however, it results that for each heat exchanger with a different number of flat tubes, a new punching tool has to be provided for the production of the base, which is expensive and laborious. In the second embodiment, the base is produced as material sold by the metre, which enables a high flexibility with regard to different sizes of heat exchangers. In this embodiment, all the passages in the base are embodied identically, which requires that the lateral part must be inserted through a passage, through which also the flat tubes could be inserted. For this reason, the lateral part has the same dimensions as the flat tubes, which results, however, in comparatively thick and therefore also heavy and expensive lateral parts.

SUMMARY

The present invention is therefore concerned with the problem of indicating for a heat exchanger of the generic type an improved or at least alternative embodiment, which permits a favourably priced, light and, at the same time, flexible production.

This problem is solved according to the invention by the subject of the independent claim(s). Advantageous embodiments are the subject of the dependent claims.

The present invention is based on the general idea of constructing a longitudinal end area of the lateral part of a heat exchanger no longer as a solid profile, but rather of providing it with recesses, so that on the one hand a base produced in a favourably priced manner as material sold by the metre can be used, but on the other hand also for larger passages, i.e. larger flat tubes, a comparatively light and nevertheless stable lateral part can be used. The heat exchanger according to the invention, which can be constructed for example as a charge air cooler, has two bases, which respectively have passages for receiving, on the longitudinal end sides, fluid-conducting tubes, in particular coolant-conducting flat tubes. At least one collecting chamber is also provided, which is arranged on one of the bases or respectively is connected therewith. The said lateral parts form a lateral termination of the heat exchanger, which lateral parts are respectively received with a longitudinal end area at least partially in an end-side passage of the associated base. According to the invention, this longitudinal end area of the lateral part is now formed in the shape of a beam and has at least one recess, whereby a cross-sectional surface of the longitudinal end area is smaller than a cross-sectional surface of the associated end-side passage, and wherein a maximum material thickness of the longitudinal end area is smaller in the direction of the longitudinal extension of the base than the height of the end-side passage, also viewed in longitudinal extension of the base. Hereby, it is possible to produce a comparatively light—as it is distinctly more delicate—lateral part with an equally great bending stiffness, which at the same time is also suitable for heat exchangers with large tube heights. Through the recess provided at least in the area on the longitudinal end side, a considerable saving of material and therefore also a considerable reduction in cost and weight can be achieved compared to a rectangular solid profile. A further advantage results from the fact that no separate end-side passages have to be produced on the respective base with a smaller cross-section than the other passages, so that a continuous base can be used.

In an advantageous further development of the solution according to the invention, the longitudinal end area of the lateral part, received by the end-side passage, has at least one lug projecting in longitudinal direction. This lug can form, for example, an integral component of the lateral part and has, furthermore, preferably the same material thickness or respectively material strength as the lateral part itself. Through a simple bending of the lug with the lateral part inserted in the end-side passage, in addition the collecting chamber can be connected comparatively simply to the base or respectively can be pressed against the latter. As a seal usually runs between the collecting chamber and the base, the lugs can be used in addition for producing the sealing effect. Of course, the lugs or respectively the at least one lug have here a material thickness which allows the lug to be bent around an axis parallel to the width of the passage.

Expediently, the longitudinal end area of the lateral part has a meandering, wave-like, U-shaped, L-shaped or H-shaped cross-section. This non-conclusive list already outlines what diverse embodiments are possible for the cross-section profile of the lateral part. Here, the cross-sectional shape can be maintained continuously over the entire longitudinal extension of the lateral part, or else a central portion can also be provided, which has a different cross-section profile than the longitudinal end areas of the lateral part. In the most favourable case, i.e. therefore for example with a constant cross-section profile, the lateral part can also be constructed as an extruded section. Purely theoretically, however, it is course also conceivable that the lateral part has a central portion between the two longitudinal end areas, the cross-sectional surface of which is smaller than the cross-sectional surface at least of one of the lateral longitudinal end areas. It is also possible to compose the lateral part from three separate individual parts, wherein these three individual parts are connected to one another in a materially bonded manner. Through, for example, the meandering and/or wave-like or H-shaped cross-section, furthermore a lateral part with a comparatively high bending stiffness can be produced in a simple manner.

In an advantageous further development of the solution according to the invention, the cross-sectional surfaces and the contours of all passages, i.e. also of the end-side passages of a base are the same, i.e. identical. Hereby, a particularly simple, high-quality and favourably priced series production of the base as endless base is possible, whereby heat exchangers of different size are able to be produced in a simple manner through different cutting to length of the base.

Further important features and advantages of the invention will emerge from the subclaims, from the drawings and from the associated figure description with the aid of the drawings.

It shall be understood that the features mentioned above and to be explained further below are able to be used not only in the respectively indicated combination, but also in other combinations or in isolation, without departing from the scope of the present invention.

Preferred example embodiments of the invention are illustrated in the drawings and are explained further in the following description, wherein the same reference numbers refer to identical or similar of functionally identical components.

BRIEF DESCRIPTION OF THE DRAWINGS

There are shown, respectively diagrammatically,

FIG. 1 a heat exchanger according to the invention, in a side view,

FIG. 2 different views onto a heat exchanger according to the invention in the region of a lateral part inserted into an end-side passage of a base, with inserted seal,

FIG. 3 a base configured as a continuous base,

FIG. 4 a detail view of FIG. 1 with lateral part inserted in the end-side passage and with bent lugs,

FIG. 5 a view onto a heat exchanger according to the invention with lugs not yet bent, on a longitudinal side,

FIG. 6 a heat exchanger, in which the lugs on the lateral part side are arranged offset by half a pitch to the passages,

FIG. 7 a view onto a longitudinal side of the base with local deformations for fixing the collecting chamber on the base,

FIG. 8 a sectional illustration through the heat exchanger in the region of the base and of the collecting chamber with a clamp for fixing the collecting chamber on the base,

FIG. 9 a detail illustration of the connecting area between base and tubes with a stop,

FIG. 10 a lateral part with lugs and additional extensions for positioning the collecting chamber,

FIG. 11 a detail illustration onto a lateral part with different portions.

DETAILED DESCRIPTION

According to FIGS. 1 to 7 and 9 to 11, a heat exchanger 1 according to the invention, which can be constructed for example as a charge air cooler or as a coolant cooler, has two bases 2, of which often however only a single one is illustrated in the figures. Each of these bases 2 has passages 3 for the end-side receiving of fluid-conducting tubes 4, for example flat tubes. A collecting chamber 5 (cf. FIGS. 1, 4, 5, 7, 8 and 11) is likewise provided, which is arranged on one of the bases 2. The base 2 with the associated collecting chamber 5 forms here a collector, for example for refrigerant or coolant. A lateral part 6 is also provided, normally of course two lateral parts 6, which are received respectively with a longitudinal end area 7 at least partially in an end-side passage 8 of the associated base 2. Usually, the last passage of the base 2 in longitudinal direction is regarded here as end-side passage 8. According to the invention, the longitudinal end area 7 of the lateral part 6 is formed in the shape of a beam and has at least one recess 9, so that a cross-sectional surface of the longitudinal end area 7 is smaller than a cross-sectional surface of the associated end-side passage 8. A maximum material thickness s (cf. FIG. 2) of the longitudinal end area 7 is smaller here in the direction of the longitudinal extension 10 of the base 2 than the height h of the end-side passage 8. Hereby, it is possible for the first time to construct the lateral part 6 on the one hand so as to be comparatively light and on the other hand so as to be comparatively rigid, and at the same time to use continuous bases as bases 2 which with regard to their manufacture are able to be produced in a simple and favourably priced manner. In the case of bases hitherto, it was necessary in particular in the case of large heat exchangers with comparatively large tubes 4, to either provide smaller end-side passages 8 for the lateral parts 6, which was laborious with regard to manufacture, because separate punching tools were necessary, or else to use comparatively large and therefore also heavy and expensive lateral parts 6, which were able to be used with identical passages 3, 8.

Observing, furthermore, FIGS. 2, 4, 6, 7 and 10 and 11, it can be seen that the longitudinal end area 7 of the lateral part 6, received by the end-side passage 8, has at least one lug 11. This lug 11 has a material thickness which allows the lug 11 to be bent around an axis 12 parallel to the broad side 15 of the passage 8, and to fasten the collecting chamber 4 to the base 2 by means of it.

The longitudinal end area 7 of the lateral part 6 can have here a meandering or respectively wave-like cross-section, as is illustrated for example according to FIGS. 2, 6 and 10, wherein of course also U-shaped, L-shaped or H-shaped cross-sections are conceivable. All these cross-sections have here the great advantage on the one hand of being comparatively light and requiring little material for a comparatively high bending stiffness. The lugs 11 arranged on the longitudinal end area 7 preferably have a uniform material thickness with respect to the material thickness s of the longitudinal end area 7, wherein the longitudinal end area 7 of the lateral part 6 and/or the lug 11 formed on the longitudinal end area 7 have/has in cross-section a uniform material thickness s. The collector is sealed by a seal 13 (cf. FIG. 2), which circulates on the base (2) and extends on the longitudinal side in a groove bottom of the base (2) and on the narrow side runs between two passages (3, 8). With the lateral part 6 according to the invention it is possible, furthermore, to manufacture the base 2 with identical passages 3, 8 and thereby to produce it as a continuous base which is able to be produced at a favourable cost.

The lateral part 6 is formed in a punching- and/or stamping process so that in assembled state at least one outer side lies against an inner side of the end-side passage 8 and can be tightly connected therewith, soldered for example. Observing FIG. 2, it can be seen for example that the longitudinal end area 7 of the lateral part 6 lies against the broad side 14 of the passage 8 facing the nearest longitudinal-side end of the base 2, wherein the lug 11 is formed adjacent to this broad side 14. Purely theoretically, the longitudinal end area 7 of the lateral part 6 can of course also lie against a broad side 15 of the passage 8 facing the remote longitudinal-side end of the base 2, wherein the lug 11 is then formed adjacent to this broad side 15. Such an embodiment is, however, not illustrated in the drawings.

From FIGS. 2 and 6 and 10 it can be seen, furthermore, that the longitudinal end area 7 of the lateral part 6 lies against all four inner surfaces of the end-side passage 8 in certain areas or respectively repetitively in sections, which contributes to a particularly high stiffening.

For fixing the collecting chamber 5 on the base 2, the lugs 11 can be bent around an edge thereof, wherein alternatively provision can also be made that on the collecting chamber 5 an edge region is provided with a recess 16 (cf. FIG. 7), in which the lateral part 6, in particular the lug 11 of the lateral part 6, is at least partially received. The collecting chamber 5 can, furthermore, be fastened on the base 2 by a wave-slot flanging (see FIG. 4), battlement connection 21 (see FIG. 6, 9) or crimp connection 22 (see FIG. 8) by deforming of fixing means arranged at least in longitudinal direction of the base 2. The fixing means themselves can be arranged spaced periodically apart from one another here on a base channel and can either be aligned with the passages 3 or with the intermediate regions between the passages 3. Of course, the collecting chamber 5 can also be fixed on the base 2 by means of a clamp 17 (cf. FIG. 8).

Observing FIG. 9, it can be seen that the lateral part 6 has at least partially in the region of the network an altered shape compared to the part of the lateral part 6 situated in the passage 6, to the effect that the altered shape forms a stop 18 for the base 2 and hereby in the joined state the distance between base 2 and stop 18 is less than or equal to 1 mm. The lateral part 6 alongside the lug 11 can have an extension 19 (cf. FIG. 10) for positioning the lateral part 6, which is placed around at least partially contrary to the bending direction of the lug 11 and hereby forms on the rear side of the base 2 a fixing of the lateral part 6 with respect to the base 2 in longitudinal direction.

Generally, the lateral part 6 can be constructed in one part and in particular also in one piece, in particular as an extruded section, so that the longitudinal end areas 7 are constructed identically to a central portion 20, wherein of course it is also conceivable that the central portion 20 has a different cross-section, as is illustrated for example according to FIGS. 1 and 11, wherein the cross-sectional surface of the central portion 20 is smaller than the cross-sectional surface at least of one of the lateral end areas 7, whereby again a saving of material and therefore also a saving of weight can be achieved. In this case, provision can be made that the lateral part 6 is embodied in several parts, wherein the two longitudinal end areas 7 are connected in a materially bonded manner with the central portion 20, for example are soldered or welded.

Several advantages can be achieved with the heat exchanger 1 according to the invention:

-   -   The lateral part 6 can be embodied overall so as to be lighter         but nevertheless with the same bending stiffness, and in this         manner can also be used in bases 2 with identical passages 3, 8,         so that the bases 2 can be manufactured as favourably priced         continuous bases,     -   through the special shaping of the lateral part 6 in the region         of the end-side passage 8, an improved support of the corner         tube (the tube 4 nearest to the lateral part 6) against bending         can take place, whereby a reduction of the tension in the base         region of the corner tubes can be brought about,     -   the lateral part 6 can, furthermore, be embodied in several         parts, which enables longitudinal expansion portions, which are         necessary for the equalization of the temperature expansion, to         be dispensed with. 

1. A heat exchanger, comprising: at least two bases respectively having a passage for receiving a plurality of fluid-conducting tubes on a longitudinal end side; at least one collecting chamber arranged on at least one of the at least two bases; at least one lateral part received via a longitudinal end area at least partially in an end-side passage of an associated base of the at least two bases; and wherein the longitudinal end area of the at least one lateral part has a beam shape and at least one recess, and the longitudinal end area has a cross-sectional surface that is smaller than a cross-sectional surface of the end-side passage of the associated base, and wherein a predefined material thickness of the longitudinal end area is smaller in a direction of a longitudinal extension of the associated base than a height of the end-side passage.
 2. The heat exchanger according to claim 1, wherein the longitudinal end area of the at least one lateral part received by the end-side passage includes at least one lug.
 3. The heat exchanger according to claim 2, wherein the at least one lug has a material thickness such that the at least one lug is bendable around an axis parallel to a broad side of the end-side passage.
 4. The heat exchanger according to claim 2, wherein the at least one lug in a bent state fixes the at least one collecting chamber on the at least one base.
 5. The heat exchanger according to claim 3, wherein the longitudinal end area of the at least one lateral part lies against a broad side of the end-side passage facing a proximal longitudinal-side end of the associated base, and wherein the at least one lug is disposed adjacent to the broad side.
 6. The heat exchanger according to claim 1, wherein the longitudinal end area of the at least one lateral part includes at least one of a meandering cross-section, a wave-like cross-section, a U-shaped cross-section, a L-shaped cross-section and a H-shaped cross-section.
 7. The heat exchanger according to claim 1, wherein the longitudinal end area of the at least one lateral part lies in certain areas against a plurality of inner surfaces of the end-side passage.
 8. The heat exchanger according to claim 1, wherein the longitudinal end area of the at least one lateral part has a surface lying against the end-side passage that is soldered at least in certain areas to a corresponding surface of the end-side passage.
 9. The heat exchanger according to claim 1, wherein the at least one lateral part includes a central portion disposed between two longitudinal end areas, the central portion having a cross-sectional surface that is smaller than the cross-sectional surface of at least one of the two longitudinal end areas.
 10. The heat exchanger according to claim 1, further comprising a circumferential seal disposed in a groove bottom on a longitudinal side of the associated base and extends on a narrow side between the passage and the end-side passage.
 11. The heat exchanger according to claim 1, wherein the cross-sectional surface of the passage and the end-side passage of the associated base are identical.
 12. The heat exchanger according to claim 2, wherein the at least one collecting chamber has an edge region provided with a recess, the recess receiving the at least one lateral part via the at least one lug.
 13. The heat exchanger according to claim 1, wherein the at least one collecting chamber is secured to the at least one base by deformation of a fixing element arranged at least in a longitudinal direction of the at least one base, and wherein the fixing element includes at least one of a wave-slot flanging and a battlement connection.
 14. The heat exchanger according to claim 13, wherein the fixing element includes a plurality of fixing elements arranged spaced apart from one another periodically on a base channel and aligned with one of the passages and an intermediate areas spaced from the passage.
 15. The heat exchanger according to claim 1, wherein the at least one collecting chamber is fixed on the at least one base via a clamp.
 16. The heat exchanger according to claim 1, wherein the at least one collecting chamber has an edge region provided with a recess, and the at least one lateral part is received in the recess at least partially.
 17. The heat exchanger according to claim 2, wherein the at least one lateral part includes a central portion disposed between two longitudinal end areas, and wherein the central portion has a cross-sectional surface that is smaller than the cross-sectional surface of at least one of the two longitudinal end areas.
 18. The heat exchanger according to claim 3, wherein the longitudinal end area of the at least one lateral part lies against a broad side of the end-side passage facing a remote longitudinal-side end of the associated base, and wherein the at least one lug is disposed adjacent to the broad side.
 19. The heat exchanger according to claim 3, wherein the at least one lug secures the at least one collecting chamber and the at least one base together when the at least one lug is bent.
 20. A heat exchanger, comprising: at least two bases respectively having a passage for receiving a plurality of fluid-conducting tubes on a longitudinal end side; at least one collecting chamber arranged on at least one of the at least two bases; at least one lateral part received via a longitudinal end area at least partially in an end-side passage of an associated base of the at least two bases; at least one lug disposed on the longitudinal end area of the at least one lateral part received by the end-side passage; and wherein the longitudinal end area of the at least one lateral part has a beam shape and at least one recess, and the longitudinal end area has a cross-sectional surface that is smaller than a cross-sectional surface of the end-side passage of the associated base, and wherein a predefined material thickness of the longitudinal end area is smaller in a longitudinal direction of the associated base than a height of the end-side passage. 